US9549547B2 - Regeneration of antimicrobial coatings containing metal derivatives upon exposure to aqueous hydrogen peroxide - Google Patents

Regeneration of antimicrobial coatings containing metal derivatives upon exposure to aqueous hydrogen peroxide Download PDF

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Publication number
US9549547B2
US9549547B2 US14/396,033 US201314396033A US9549547B2 US 9549547 B2 US9549547 B2 US 9549547B2 US 201314396033 A US201314396033 A US 201314396033A US 9549547 B2 US9549547 B2 US 9549547B2
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polymer
coating
hydrogen peroxide
coatings
zno
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US20160037766A1 (en
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William Toreki
Rustom S. Kanga
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Quick Med Technologies Inc
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Quick Med Technologies Inc
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Assigned to QUICK-MED TECHNOLOGIES, INC. reassignment QUICK-MED TECHNOLOGIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KANGA, RUSTOM S., TOREKI, WILLIAM
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    • A01N25/00—Biocides, pest repellants or attractants, or plant growth regulators, characterised by their forms, or by their non-active ingredients or by their methods of application, e.g. seed treatment or sequential application; Substances for reducing the noxious effect of the active ingredients to organisms other than pests
    • A01N25/08—Biocides, pest repellants or attractants, or plant growth regulators, characterised by their forms, or by their non-active ingredients or by their methods of application, e.g. seed treatment or sequential application; Substances for reducing the noxious effect of the active ingredients to organisms other than pests containing solids as carriers or diluents
    • A01N25/10—Macromolecular compounds
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    • A01N59/00—Biocides, pest repellants or attractants, or plant growth regulators containing elements or inorganic compounds
    • A—HUMAN NECESSITIES
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    • A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
    • A01N59/00—Biocides, pest repellants or attractants, or plant growth regulators containing elements or inorganic compounds
    • A01N59/16—Heavy metals; Compounds thereof
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
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Definitions

  • This invention pertains to regenerable coatings with durable antimicrobial properties.
  • HAIs hospital acquired infections
  • Hydrogen peroxide is currently receiving renewed attention as a safe, environmentally-friendly, and cost-effective antimicrobial, as evidenced by the recent introduction of several commercially-available cleaning products based on HP.
  • Antimicrobial cleaning products based on hydrogen peroxide have recently been commercialized for hospital and home use by several leading brands, including Clorox and Lysol. Unfortunately, since HP is volatile, surfaces cleaned with these products (or even with alcohol, bleach, etc.) lose the antimicrobial effect immediately after drying.
  • Hospitals, nursing homes, and other healthcare facilities are known to be a breeding ground for a variety of infectious diseases.
  • the pathogens that cause these diseases can reside in many places in the hospital environment including floors, curtains, telephones, bedding, bed rails, chairs and chair backs, hand rails, and computer keyboards.
  • HAIs hospital acquired infections
  • 1 in 20 hospital patients will be infected with an HAI as a direct result of the care they receive at hospital institutions (Scott II, R. Douglas; “The Direct Costs of Healthcare-Associated Infections in U.S. Hospitals and the Benefits of Prevention”, Division of Healthcare Quality Promotion: National Center for Preparedness, Detection, and Control of Infectious Diseases, Centers for Disease Control and Prevention, (2009).
  • HAIs hospital acquired infections
  • HAIs human immunodeficiency virus
  • the direct costs of these HAIs to hospitals are estimated to be between $28.4 and $45 billion per year in the U.S. (Scott 2009).
  • These increased costs result from longer hospitalizations, increased use of diagnostic imaging, increased use of intensive care, and increased use of newer more expensive antibiotics.
  • Assuming a 20%-70% HAI prevention range, preventing HAIs can have cost benefits from $5.7 billion to $31.5 billion.
  • Hydrogen peroxide is a favored antimicrobial in many applications because its breakdown products, water and oxygen, are innocuous, and it tends to have broad spectrum antimicrobial activity, meaning that it is not only effective against bacteria, but it also kills viral and fungal organisms. Broad spectrum activity is important in situations where harmful organisms are present but their identity is not known. Hydrogen peroxide is a well-known antiseptic which has been extensively employed in aqueous solution for the treatment of infectious processes in both human and veterinary topical therapy. Both HP and zinc oxide (ZnO) have received GRAS (Generally Recognized as Safe) designations from the U.S. Food and Drug Administration (FDA). Both are also widely-available and relatively-inexpensive commodity materials.
  • GRAS Generally Recognized as Safe
  • Zinc oxide has received much attention in recent years as an antimicrobial agent. It has been found that ZnO nanoparticles show a higher efficacy than conventional ZnO powders in the micron size range. This is to be expected, based on the higher surface area of the nanoparticles. Indeed, high antimicrobial efficacy is realized for ZnO nanoparticles in suspension (i.e.
  • Silicon wafers coated with ZnO showed only a 10% reduction in 24-hour biofilm formation (Gittard, Shaun D.; Perfect, John R.; Montiero-Riviere, Nancy A; Wei, Wei; Jin, Chunming; and Narayan, Robert, J.; “Assessing the Antimicrobial Activity of Zinc Oxide Thin Films Using Disk Diffusion and Biofilm Reactor”, Applied Surface Science 255(11), p 5806-5811, (2009).
  • the point here is that although ZnO, even in nanoparticulate form, is widely touted as having antimicrobial properties, it is relatively ineffective when incorporated into coatings or composites.
  • the current invention will increase the antimicrobial efficacy of coatings containing ZnO by a few orders of magnitude (to at least the 3-log to 6-log level) via reacting the coatings with cleaning agents comprising HP.
  • Zinc oxide and hydrogen peroxide are known to react with each other to form “zinc peroxide”.
  • Zinc peroxide (ZP) is used as an oxidant, an antimicrobial, a blowing agent, and in the vulcanization of rubber, and its synthesis was patented in 1903 (U.S. Pat. No. 740,832).
  • Wood patented an improved method of producing zinc peroxide, which involved using sulfuric acid to essentially hydrolyze and “soften” the ZnO for improved yield (U.S. Pat. No. 2,563,442).
  • Dana U.S. Pat. No. 4,172,841 found that a solution of zinc acetate mixed with HP was useful for producing antimicrobial textiles.
  • Zinc hydroxide is easily formed in solution by reaction of zinc salts with sodium hydroxide, but is difficult or impossible to isolate in the dry state due to conversion to ZnO as it dries.
  • ZnO on the other hand, can also be hydrolyzed back to ZH, and either ZnO or ZH can react with HP to form ZP, which can undergo a slow hydrolysis releasing HP in the presence of water.
  • the ZH/ZnO/HP/ZP system essentially involves the sequestration of HP in a reversible manner. This slow release of HP is responsible for observed antimicrobial effect of ZP-based materials.
  • the key element of the current invention is a sequestration system for storage (sequestration) and controlled release of antimicrobially-effective amounts of hydrogen peroxide.
  • Lysol (Reckitt Benckiser) has come out with an entire product line of household cleaning products based on hydrogen peroxide: “Guided by our LYSOL® Mission for Health, we are proud to introduce the innovative LYSOL® Power & FreeTM product line to consumers who are in search of trusted, powerful cleaning agents that help to maintain a healthy home by using the very common, yet very effective household staple of hydrogen peroxide,” (see http://www.prnewswire.com/news-releases/lysol-launches-line-of-hydrogen-peroxide-products-that-marks-a-new-era-in-household-cleaning-165569576.html).
  • Lysol's general purpose cleaner lists 0.9% HP as the active ingredient.
  • Clorox has recently introduced a line of HP-based cleaners and wipes for hospital use—“Clorox HealthcareTM Hydrogen Peroxide Cleaner Disinfectants” (see http://www.cloroxprofessional.com/products/clorox-healthcare-hydrogen-peroxide-cleaner-disinfectants/at-a-glance/).
  • the Clorox Material Safety Data Sheet lists “1 to 5%” as the concentration of HP.
  • An embodiment of the present invention is a method of enhancing and regenerating durable antimicrobial activity of the surface of an article, wherein said method comprises the steps in sequence of:
  • said metal derivative comprises 1% to 50% (w/w) of the weight of the doped polymer, wherein said metal derivative is a hydroxide, an oxide, or a peroxide of a metal selected from the group consisting of zinc, magnesium, titanium, and zirconium,
  • water absorbency of said polymer is between 0.5% and 20% (w/w), wherein said polymer doped with said metal derivative has been determined to be capable of sequestering hydrogen peroxide when exposed to said source of aqueous hydrogen peroxide;
  • said antimicrobial activity when tested using ASTM Standard Method E2180 at least 24 hours after said removal of the source of hydrogen peroxide, provides at least a 3-log reduction of viable Escherichia coli bacteria greater than that of a corresponding surface of said polymer doped with said metal derivative which has not been exposed to hydrogen peroxide.
  • the above method may further comprise the step of;
  • the metal derivative is selected from the group consisting of zinc hydroxide, zinc peroxide, zinc oxide, zinc oxide nanoparticles, and zinc oxide micron particles. More preferably the metal derivative is selected from the group consisting of zinc oxide nanoparticles and zinc oxide micron particles.
  • the metal derivative comprises 10% to 30% (w/w) of the weight of the doped polymer.
  • Suitable polymers of the invention are selected from the group consisting of polyacrylonitrile, acrylonitrile butadiene styrene (ABS) polymer, acrylic (PMMA), celluloid, cellulose acetate, ethylene-vinyl acetate (EVA), ethylene vinyl alcohol (EVOH), fluoropolymers (PTFE, FEP, PFA, CTFE, ECTFE, ETFE), ionomers, acrylic/PVC alloy, liquid crystal polymer (LCP), polyacetal (POM or Acetal), polyacrylates (acrylic), polyacrylonitrile (PAN or acrylonitrile), polyamide (PA or Nylon), polyamide-imide (PAI), polyaryletherketone (PAEK or Ketone), polybutadiene (PBD), polybutylene (PB), polybutylene terephthalate (PBT), polycaprolactone (PCL), polychlorotrifluoroethylene (PCTFE), polyethylene terephthalate (PET), polycyclo
  • a preferred polymer of the invention is selected from the group of polyurethanes, polyacrylates, and polyvinyl acetate.
  • the doped polymer is a mixture that further comprises a hydrophilic acrylic polymer.
  • the source of aqueous hydrogen peroxide for the process desirably has a concentration of hydrogen peroxide between 0.5% and 10%. Preferably the concentration of hydrogen peroxide is between 1% and 5%.
  • the hydrogen peroxide source may be a commercial cleaner containing at least 0.5% hydrogen peroxide.
  • the doped polymer is exposed to hydrogen peroxide for 1 minute to 30 minutes. Longer exposure times are acceptable.
  • a preferred method to assay the level of sequestered hydrogen peroxide is a colorimetric spot test.
  • regenerable antimicrobial coating comprising,
  • water absorbency of said polymer is between 0.5% and 20% (w/w), wherein said polymer doped with said metal derivative has been determined to be capable of sequestering hydrogen peroxide when exposed to said source of aqueous hydrogen peroxide; wherein the antimicrobial activity of said doped polymer can be regenerated on subsequent exposure to aqueous hydrogen peroxide,
  • said antimicrobial coating when tested using ASTM Standard Method E2180 at least 24 hours after preparation, provides at least a 3-log reduction of viable Escherichia coli bacteria greater than that of a corresponding coating which has not been exposed to hydrogen peroxide.
  • the regenerable antimicrobial coating comprises a polymer selected from the group consisting of polyacrylonitrile, acrylonitrile butadiene styrene (ABS) polymer, acrylic (PMMA), celluloid, cellulose acetate, ethylene-vinyl acetate (EVA), ethylene vinyl alcohol (EVOH), fluoropolymers (PTFE, FEP, PFA, CTFE, ECTFE, ETFE), ionomers, acrylic/PVC alloy, liquid crystal polymer (LCP), polyacetal (POM or Acetal), polyacrylates (acrylic), polyacrylonitrile (PAN or acrylonitrile), polyamide (PA or Nylon), polyamide-imide (PAI), polyaryletherketone (PAEK or Ketone), polybutadiene (PBD), polybutylene (PB), polybutylene terephthalate (PBT), polycaprolactone (PCL), polychlorotrifluoroethylene (PCTFE), polyethylene terephthalate (PET
  • the polymer is selected from the group of polyurethanes, polyacrylates, and polyvinyl acetate.
  • the doped polymer may be a mixture that further comprises a hydrophilic acrylic polymer.
  • the regenerable antimicrobial coating may be a UV-curable coating, water-borne coating, or solvent-borne coating.
  • a typical regenerable antimicrobial coating comprising a UV-curable coating may further comprise a binder; curing agents; stabilizers; an acrylate oligomer; a urethane oligomer, a crosslinking agent such as tris (2-hydroxy ethyl) isocyanurate triacrylate and/or hexane diol diacrylate, a defoamer, a thermal stabilizer, a non-blocking slip additive, a photoinitiator, a near-UV photoinitiator, or mixtures thereof.
  • a typical regenerable antimicrobial coating comprising a water-borne coating may further comprise a self-crosslinking linking acrylic dispersion, a UV curable polyurethane dispersion, or a self-crosslinking polyurethane dispersion, and further comprise an alcohol, a glycol, defoamers, photoinitiators, thermal stabilizers, anti-oxidants, surfactants or mixtures thereof.
  • a typical regenerable antimicrobial coating comprising a solvent-borne coating may further comprise a solvent selected from the group of methylethylketone, ethanol, and mixtures thereof; and a coating polymer selected from the group consisting of polyvinyl acetate and polyvinyl acetate-crotonic acid copolymer; and further comprise defoamers, photoinitiators, thermal stabilizers, anti-oxidants, surfactants or mixtures thereof.
  • the article may be selected from the group consisting of medical implants; medical instruments or devices; hospital equipment; bed rails; table tops; bedpans; i.v. stands; lamp handles; blood pressure cuffs; dental equipment; surgical instruments; orthopedic devices; hot/cold packs; wheelchair cushions; doorknobs; bathroom fixtures; food preparation surfaces; equipment touch-screens; floor waxes; paints; inks; clear coats; varnish; kitchen equipment and tables in restaurants, schools, and other institutions; home appliances; and seats, armrests, railings, and tray tables for airlines and other public transportation.
  • Doping refers the process of infusing, mixing, or otherwise adding a metal derivative to a polymer, which aids in changing the physical and chemical properties of the overall mixture.
  • Antimicrobial refers to the microbicidal or microbistatic properties of a compound, composition, formulation, article, or material that enables it to kill, destroy, inactivate, or neutralize a microorganism; or to prevent or reduce the growth, ability to survive, or propagation of a microorganism.
  • Article refers to a solid which may be rigid or flexible.
  • an article having a surface with durable antimicrobial activity is either capable of being coated with doped polymer or is comprised of such a doped polymer.
  • “Surface” refers to the common outside surface of the article including any coating thereon.
  • “Durable” means that the antimicrobial activity of an article remains after the article is treated. is washed or laundered one or more times, or that the antimicrobial activity persists for a significant portion of the expected useful lifetime of the treated substrate under normal use conditions.
  • Metal Derivative means an ion, salt, complex, hydrated ion, an ionic complex, a complex of an ion with hydrogen peroxide, a metal hydroxide species, a metal oxide species, or a metal peroxide species, or mixtures thereof, derived from one or more metallic elements for use in the invention.
  • Preferred for use in this invention are metal derivatives of zinc, magnesium, or zirconium.
  • the alkali metals lithium, sodium, potassium, rubidium, cesium, and francium
  • This invention relates to regenerable antimicrobial coatings with durable antimicrobial efficacy for use in medical applications including implants, medical instruments or devices, and hospital equipment.
  • the same coatings have broad utility in the consumer, industrial, and institutional markets for example for the preparation of floor waxes and paints having regenerable antimicrobial activity.
  • the coating technology is based on sequestration of hydrogen peroxide (HP) by binders based on metal derivatives such as zinc oxide incorporated into the coatings. Coatings could be applied to key “frequent touch” areas where microbial contamination occurs—particularly those areas that can (or need to) be periodically cleaned. This includes, for example, countertops, bathroom fixtures, doorknobs, railings, and appliances. Materials to be coated would include, for example, metal, plastic, fiberglass, porcelain, and stone.
  • coated surfaces would be cleaned regularly with a cleaner containing HP. With each cleaning, the antimicrobial properties of the coated surfaces would be regenerated.
  • the same polymers used for coatings can also be fabricated into polymer articles or device with durable antimicrobial activity, such as by casting, molding, extrusion, etc.
  • zinc oxide particulates or fillers may be incorporated into coatings as binders for HP for use in applications where durable and regenerable antimicrobial protection is needed.
  • Exposure of coated surfaces to HP solutions, or commercially-available HP-containing cleaning products can cause binding of HP to the zinc oxide particles; allowing HP to be sequestered within the coating after the surface has dried.
  • This imparts a durable and long-lasting antimicrobial effect to the surface sufficient to reduce or eliminate the proliferation and spread of pathogenic organisms in-between cleaning cycles. Additionally, the antimicrobial effect is regenerated each time the surface is cleaned with an HP-containing solution.
  • An embodiment of the invention is a novel polymer coating which sequesters HP into a coated surface, keeping it there in active form even after the applied HP solution or cleaning product has long since dried or evaporated. This allows the surface to maintain long-lasting antimicrobial effects between cleanings. Data is presented herein to demonstrate that these coated and HP-exposed surfaces can kill greater than 99.9999% of microbes which contact the surface, even weeks after the HP exposure.
  • the polymer coatings bind hydrogen peroxide (HP), even after the surface has dried, thus maintaining sanitized surfaces and preventing microbial growth and the spread of disease.
  • HP hydrogen peroxide
  • the coatings were developed with medical and hospital applications in mind, the potential for use in other areas are enormous, with broad utility in the consumer, industrial, and institutional markets. Examples of places where such coatings would have particularly helpful impact include bathroom fixtures in public restrooms; kitchen equipment and tables in restaurants, schools and other institutions; home appliances; or seats, armrests, railings, and tray tables for airlines and other public transportation.
  • Such coatings could be easily implemented into existing manufacturing processes, retrofitted to existing equipment, or even sold as paints for DIY use. Widespread use of safe “green” HP technology would help to overcome the public's perception of antimicrobials as “toxic chemicals”.
  • Another embodiment of this invention is a method to fabricate polymeric coatings or polymeric objects or articles which contain zinc oxide particles capable of binding and sequestering hydrogen peroxide in order to impart durable antimicrobial properties to the coatings, objects or articles even after the HP-based cleaning solution has dried or evaporated.
  • the method comprises the steps of incorporating candidate particles into a model coating system, and then evaluating the antimicrobial efficacy of the coating after exposure to hydrogen peroxide.
  • One may vary relevant parameters such as particle composition and size, particle loading, and polymer composition will be varied in order to optimize antimicrobial performance.
  • Polymer composition may be varied by adjusting parameters such as hydrophilicity, crosslink density, or water-absorbing capacity.
  • the “self-sterilizing” surfaces resulting from the above outlined method would be broadly applicable in a wide range of places and applications, and widespread use would contribute significantly to the reduction of contaminated surfaces.
  • the spread of disease and infection could be significantly reduced, leading to better health for all segments of the population, as well as a significant reduction in healthcare costs.
  • zinc oxide particles and nanoparticles are available from commercial suppliers.
  • the zinc oxide particles vary not only in size, but also in shape, and crystallinity. Many are available in dry or suspended form. There are many different forms of ZnO that may be useful for the invention.
  • the zinc oxide particles may be incorporated into either one or both of two model coating systems, a UV-curable 100%-solids acrylate coating system, or alternatively, a water-borne, UV-curable polyurethane (PU) dispersion system.
  • These coatings may be in the form of inks, paint, varnish, clear-coats, or similar materials, and could be applied during manufacture of a device, or sold as post-treatments.
  • Appropriate methods for evenly dispersing particulates into these coatings systems include processes such as simple mixing, media milling, high pressure homogenization, and the use of ultrasonics.
  • Test coatings may be fabricated on Mylar sheets or other substrates which are easily handled for testing.
  • a coating on thin transparent Mylar (polyester) film is convenient for testing because it allows for easy cutting and testing of the coated material.
  • Mixtures of zinc oxide particles and coating formulations found to have acceptable dispersion properties can readily be fabricated into coatings having approximately 5 to 20 microns in thickness.
  • the comparative antimicrobial performance of the as-produced coatings can be evaluated using two standard ASTM antimicrobial performance methods (Agar Slurry and Shake Flask methods) using both Gram+ and Gram ⁇ organisms (such as Staph. aureus and E. coli ).
  • ASTM antimicrobial performance methods Agar Slurry and Shake Flask methods
  • Gram+ and Gram ⁇ organisms such as Staph. aureus and E. coli.
  • the comparative testing of the coating after exposure to commercially-available HP-based cleaning products, or after prolonged exposure to higher concentrations of HP provides a measure of the enhanced antimicrobial efficacy of the HP treated coatings.
  • Combinations of particles and coatings can be characterized by instrumental methods to determine the surface properties of the coatings. Coating characteristics (such as hydrophobicity and degree of crosslinking) can also be modified to enhance antimicrobial performance.
  • the general concept of this invention is to incorporate active metal oxide particulates such as zinc oxide into coatings for substrates such as medical devices such as implants, medical instruments or devices, and hospital equipment, or for manufacture of such articles from the polymers described herein.
  • substrates such as medical devices such as implants, medical instruments or devices, and hospital equipment
  • substrates and devices include, for example: bed rails; table tops; bedpans; i.v. stands; lamp handles; blood pressure cuffs; dental equipment; surgical instruments; orthopedic devices, hot/cold packs, wheelchair cushions
  • the invention is applicable for use on other common surfaces such as doorknobs, bathroom fixtures, food preparation surfaces, and equipment touch-screens—not just in hospitals, but also for institutional use (schools, prisons, restaurants, etc.), as well as in common household applications.
  • Coatings can be applied at the time of manufacture of specific articles, devices, or surfaces. Alternatively, the required coatings can be applied at the point of use (much like paint, varnish, or floor wax).
  • regenerable ZnO binder for hydrogen peroxide locked into a polymer matrix can be widely applicable to almost any kind of existing coating system. Examples include 100% solids UV curable coatings, water-borne dispersions, solvent-borne coatings, extrusion coatings, and powder coatings.
  • the invention is also applicable for use with all types of composites, or thermoplastics, and in virtually any molded, extruded, or melt blown type of application, such as thermoplastic polyurethanes, rubber, and silicone.
  • Regenerable antimicrobial coatings comprising 100% solids UV radiation curable coatings readily incorporate metal oxide particles using well known and studied milling processes. Additionally, the UV curable coatings allow greater flexibility in terms of targeting specific physical property attributes required for such a coating [Idacavage, Mike J; “Introduction to the Basics of UV/EB Chemistry and Formulations”, SUNY ESF, Institute for Sustainable Materials and Manufacturing Webinar, Esstech, Inc. (2012)]. Some of those attributes are: control of surface characteristics such as hydrophobic/hydrophilic balance, scratch and abrasion resistance; speed of cure; weatherability; flexibility; ease of incorporation of inorganic oxides; high productivity; environmentally-friendly, low volatile organic compounds (VOC) emission; and adhesion to wide variety of substrates.
  • VOC volatile organic compounds
  • UV curable coatings also have some shortcomings or areas of improvements to be taken into account, including: significant shrinkage upon cure leading to unacceptable adhesion to some non-porous low surface energy substrates; line of sight process which requires other strategies for dark cure of 3-dimensional parts; thick coatings, opaque coatings, and highly pigmented coatings are difficult to cure.
  • UV-curable coating formulations are particularly useful as coating matrixes for the ZnO particulates.
  • the coating formulations will typically comprise a blend of several acrylic monomers as well as curing agents, stabilizers, and other additives. Properties such as hardness, surface texture, hydrophobicity, and permeability can be modified by adjusting the ratios of key components.
  • Typical components of the UV-curable coating include a binder such as an inert polyester resin; an acrylate oligomer such as polyethylene glycol diacrylate; a urethane oligomer such as an aliphatic urethane hexaacrylate oligomer; a crosslinking agent such as tris(2-hydroxy ethyl) isocyanurate triacrylate and/or hexane diol diacrylate.
  • Typical additives include a defoamer, a thermal stabilizer, a non-blocking slip additive, a photoinitiator, and a near-UV photoinitiator.
  • an acrylic UV-curable coating formulation is designated as SS 1.
  • the 100% solids UV curable coating solution was doped with the required amount of ZnO using a commercially available pre-dispersed Nano ZnO in a monomer such as TRPGDA.
  • Coatings from water-borne dispersions can be used advantageously for the design of a regenerable antimicrobial coating because of the variety of dispersions available, as well as ease of incorporation of metal oxide particles in the final coating.
  • Water-borne dispersions have a superior environmental edge since there is very little VOC.
  • Other advantages include: control of surface characteristics such as hydrophobic/hydrophilic balance; scratch and abrasion resistant coating upon crosslinking; ease of incorporation of inorganic oxides; high productivity; adhesion to wide variety of substrates; low or no shrinkage upon cure.
  • UV-curable acrylic dispersions or UV-curable polyurethane dispersions are particularly effective as matrixes for ZnO particulates. These types of systems show dry, non-tacky films before UV cure, and develop solvent-resistant and tough coatings after UV cure.
  • SXL self-crosslinking acrylic or polyurethane dispersion
  • the SXL dispersions start the oxidative crosslinking process immediately upon removal of water. Using heat accelerates the process but room temperature crosslinking would proceed over a period of time and form tough, solvent-resistant coatings.
  • the Nano ZnO dispersions can be incorporated quite easily in the SXL systems. Alternately, micro ZnO powders can also be dispersed in using various techniques described above.
  • a third type of polyurethane dispersion used are “physically drying” thermoplastic polyurethanes.
  • the physically drying polyurethanes are fairly high MW polyurethane particles dispersed in water and form excellent films upon water removal. They attain their final property immediately upon drying. Similar to the UV curable and SXL systems above the ZnO dispersions can be easily incorporated in the physically drying PUD systems as well.
  • the physically drying PUD can be further crosslinked if desired using a “2K” system adding an external crosslinking compound right before coating, although that might lead to shelf life issues.
  • a typical water-borne acrylic baseline coating formulation comprises water, a co-solvent such as isopropyl alcohol or a glycol ether, a binder, and a self-crosslinking linking acrylic dispersion.
  • the acrylic dispersion is a polymerized system that has self-crosslinking or UV curable groups. Upon water removal the dispersion would coalesce and form non-tacky film. Over time the properties improve for the self-crosslinking. Upon UV curing, the properties improve for the UV curable acrylic.
  • the formulation may further comprise additives such as defoamers, photoinitiators, thermal stabilizers, anti-oxidants, and surfactants. All of the components may be combined in different ratios to effect different surface properties.
  • a typical water-borne polyurethane baseline coating formulation comprises water, a co-solvent such as isopropyl alcohol or a glycol ether; a binder, a UV-curable polyurethane dispersion.
  • the polyurethane dispersion is a high molecular weight polyurethane in a stable dispersion that has self-crosslinking or UV curable groups. Upon water removal the dispersion would coalesce and form non-tacky film. Over time the properties improve for the self-crosslinking. Upon UV curing, the properties improve for the UV curable polyurethane.
  • the formulation may further comprise additives such as defoamers, photoinitiators, thermal stabilizers, anti-oxidants, and surfactants. All of the components may be combined in different ratios to effect different surface properties.
  • a third type of binder system shown as an example herein is solvent-borne coatings. Coatings based on a solid, thermoplastic, ultrahigh molecular homopolymer polyvinylacetate resins gave clear, flexible films with good gloss and resistant to oil and grease. Structure of ultrahigh molecular homopolymer polyvinylacetate resins (called Vinnapas UW4 FS) is as shown in Formula 1.
  • the resin was dissolved in MEK at 30% solids to give high viscosity liquid. It was further modified with a surface active wetting agent (Byk3440). This stock solution was XR-NSF-SB-F1 (SB-F1 for short). SB-F1 was then doped with a solvent-based Nano ZO in methoxypropylacetate.
  • UV-curable acrylics UV-curable polyurethane dispersions
  • PID UV-curable polyurethane dispersions
  • WBF1 and WBF2 Two baseline coating systems (designated as WBF1 and WBF2) were used as a matrix for the ZnO particulates. These contain the acrylic or PU resins as well as co-solvents, and other additives, which can be combined in different ratios to effect different surface properties.
  • Coatings for both types of systems can be applied to transparent Mylar film substrates for initial testing. Suitable coating thickness can range from 10 to 25 microns. These two classes of base coatings are merely representative of coatings, thermoplastics, and polymer composites in general. These two classes of coatings can be used for a variety of real-world coating applications. Furthermore, the invention should be transferrable to many other commercially important coating and fabrication systems.
  • Zinc oxide is commercially produced by oxidation of zinc vapor in air.
  • the zinc precursor may be zinc metal (direct process), or zinc ores (indirect process).
  • Zinc oxides with special properties have been made by chemical methods using zinc hydroxide intermediates (see for instance Rosenthal-Toib 2008, wherein a zinc peroxide intermediate was used). Because of the higher surface area of nanoparticles compared to micron-sized ZnO, it is expected that nanoparticles will provide higher antimicrobial efficacy due to the increased area for reaction with HP. Many ZnO nanoparticle variations are available commercially. For example, the 2011-13 Alfa-Aesar catalog lists approximately 30 different ZnO particulate products. A selection of potentially useful ZnO particulates can be chosen based on structure, chemical properties, morphology, and form. Some of these products are conveniently available in forms that lend themselves to direct incorporation into either of the two types of selected coating bases.
  • Pre-dispersed metal oxide nano-dispersions are commercially available, including NanoArc® ZnO nanoparticles from Nanophase Technologies, available as concentrated (30 wt %) dispersions in low viscosity acrylate monomers such as TPGDA (tripropyleneglycol diacrylate) and HDODA (1,6-hexanediol diacrylate). These can be directly incorporated into the 100% solids UV-curable coating system.
  • Pre-dispersed ZnO nano-dispersions in water are available in the market. These include NanoArc® Zinc Oxide nanoparticles from Nanophase Technologies, available as concentrated (50 wt %) dispersions water.
  • pre-despersed metal oxide nano-dispersions in water can be easily incorporated, pH permitting, in most water-borne dispersions described above.
  • a variety of other pre-made aqueous and non-aqueous dispersions, such as those modified with silane coupling agents, or with various dispersing agents, are also commercially available.
  • Predispersed solvent-based Nano ZO was available in methoxypropylacetate called Nanobyk 3841.
  • HP is more reactive with zinc hydroxide (ZH) than with ZnO.
  • ZH zinc hydroxide
  • zinc hydroxide is difficult to isolate in dry form since it converts to ZnO as water is taken away.
  • ZH aqueous suspensions effectively can be added to the water-borne coating system.
  • the process is as follows. ZH is synthesized by neutralization of zinc chloride/nitrate with sodium hydroxide, and used after washing to remove the salt by-products. As described above (U.S. Pat. No. 2,563,442), zinc oxide can be partially hydrolyzed to produce a “softer” and more reactive surface.
  • treatment of ZnO particles with sulfuric acid should produce a particle surface with higher reactivity towards HP.
  • a larger ZnO powder micron size range
  • these surface-modified ZnO particles can be combined with the water-borne coating system.
  • Polymerizable metal acrylates such as zinc acrylate (available from Sartomer) can be used as part of the formulation to introduce metal ions into the coating system. These can then be further reacted with hydrogen peroxide as before. In fact, it is known that HP forms complexes with zinc acetate (similar in structure to zinc acrylate) to give antimicrobial properties after drying (U.S. Pat. No. 4,172,841). Metal acrylates; however, also create hydrophobic coatings, which may affect its efficacy.
  • Another embodiment of the invention is to utilize ZnO as the inorganic binder for HP. It is known that other metal oxides (such as Zr, Mg, and Ti) can also form complexes with HP. Particulates comprising oxides of these other metals can be identified, screened for sequestration of HP, and evaluated for antimicrobial efficacy.
  • metal oxides such as Zr, Mg, and Ti
  • ZnO particles can be incorporated into coating systems such as UV 100% solids, or water-borne PU/Acrylic, or other solvent-borne coatings systems.
  • a given particle may be useful in either one or both systems.
  • premade dispersions in aqueous systems, laboratory-synthesized ZH, or acid-modified ZnO particles or polymerizable acrylate monomers are typically components in the water-borne system.
  • Zinc acrylate monomers, or dispersions of ZnO in polymerizable acrylates are more suited for the non aqueous UV-curable 100% solids system.
  • the solvent-borne ZnO systems could be utilized for both the solvent-borne coatings as well as the 100% solids UV coatings. Uniform homogenous incorporation and thorough dispersion can be achieved with relatively simple mixing, as from an overhead mixer.
  • inorganic oxides can be incorporated into the water-borne dispersions solutions using high speed, high intensity mixing. In such instances a high shear homogenizer is desirable for this purpose. As much as 40-50% of the oxides can be uniformly incorporated using these techniques, and stay suspended for a definite period of time; however, re-mixing may be required after a certain shelf life period.
  • Inorganic particulates can also be suitably dispersed using various dispersive aids. Milling or grinding of metal oxides, organic and inorganic pigments and other solids have been routinely accomplished using various types of milling processes. Those include amongst others media (or ball) milling, basket milling and 2-Roll or 3-Roll milling. Milling or grinding of metal oxides results in solutions which have significantly longer shelf life since the metal oxides are dispersed almost to the molecular state in the binder or solvents.
  • the size of the metal oxide nanoparticles allows UV- and visibly-transparent coatings, even for relatively high loadings.
  • UV curing is as efficient with the added metal oxides having particle size lower than the wavelength of light.
  • UV curing is efficient with the proper choice and range of photoinitiators.
  • a particle loading of approximately 15-20 weight percent in the final coatings is preferred. Since the particles are relatively denser than the bulk coating, this represents a smaller volume fraction.
  • the coating/particle combinations can be prepared and evaluated for homogeneity, uniformity, and stability by making test coatings. Adjustments to formulations (such as adding more crosslinking agent or UV initiator, or adjusting coating conditions) can be made in order to ensure that fully-cured, uniform and reproducible coatings are produced.
  • Test coatings can be prepared on clear, thin, flexible Mylar sheets which are easily cut for testing.
  • coatings containing dispersed ZnO particulate can be applied using a Byk coating bar or a Meyer rod to produce coatings in the 10-20 micron size range.
  • 100% solids coatings can be UV cured in a conveyer lamp oven, water-borne coatings can be air-dried prior to final UV crosslinking and the self crosslinking and physically drying systems can be cured by simply removing the water and/or solvent. Samples of each coating system without any ZnO incorporated can be used as negative controls in efficacy testing.
  • a desirable target for antimicrobial efficacy is a 3 to 6-log reduction in viable bacteria compared to an untreated control surface (i.e. a coating containing no ZnO, or a coating containing ZnO, but not exposed to HP), after the coating has been exposed to a HP solution or commercial cleaning product containing HP, tested at least 24 hours after the end of said exposure (i.e. a durable antimicrobial activity).
  • the coatings can be exposed to HP solutions prior to retesting for antimicrobial activity using the same two methods as described above.
  • one embodiment of the invention is to show that coatings can be made active using the relatively low HP concentration in a commercial product (such as Lysol 0.9%HP active), it is also an embodiment to expose samples to higher concentrations of HP and compare results.
  • a typical testing protocol is to expose samples of coatings to 10% and 3% HP solutions (optionally, with surfactant to enhance wetting of surface, and to mimic the effect of detergent in the commercial cleaning products). The samples are immersed in HP solutions for from 5 to 60 minutes then removed and allowed to air dry.
  • Coating/particulate combination(s) showing the potential for sequestering antimicrobial HP can be selected for further optimization. Characterization of the selected coating will provide information which may be valuable for learning how to modify the coatings in a positive manner.
  • the coatings may be analyzed using optical microscopy, SEM, and FTIR will show the distribution and orientation of ZnO on the coating surface. Monitoring of dyne levels (hydrophobicity) of the oxide doped coatings can be used to gage the efficacy of HP incorporation. It is expected that a higher surface of exposed ZnO will allow for more reaction with HP and thus higher efficacy. Back-scatter and EDX analysis can also show more precisely the availability of ZnO on the surface (as opposed to just the topography seen with SEM).
  • Light abrasion of the surface may cause ZnO particles that are “buried” under the coating polymer to become surface active and enhance efficacy. This effect can be investigated by checking for enhanced antimicrobial activity after repeated rubbing with a slightly abrasive applicator (such as Scotch-Brite pad) containing HP cleaning solution.
  • a slightly abrasive applicator such as Scotch-Brite pad
  • the coatings or polymer articles or objects can be enhanced include adding a higher level of particulates, or by altering coating hardness, crosslinking, or hydrophobicity. Since the hydrogen peroxide needs to react with the metal oxide in the cured coating the hydrophilic/hydrophobic balance may be critical. This can be suitably targeted by the choice of monomers or oligomers which are polar, hydrophilic and even water soluble. Several oligomers based on polyethylene glycol are used in UV curable systems to create an anti-fog coating. These function very well as a hydrophilic surface to allow efficient absorption of hydrogen peroxide into the body of the coating and to react with the high surface area nano-metal oxides. The dyne level of the coating can thus be adjusted to target the hydrophilic/hydrophobic balance.
  • the coating roughness can also play a key role.
  • Many additives are available such as flattening agents which impart matte character to the UV cured coating.
  • Other additives such as micronized polypropylene waxes provide a unique texturizing effect to the coating increasing the likelihood of efficacy of reaction between hydrogen peroxide and the metal oxide dopant.
  • the amount of HP sequestered onto the surface of coatings is measured directly by using known titration techniques. These methods involve titration of fluids in contact with the coated surface using thiosulfate or permanganate, or by a colorimetric “spot-test” using similar reagents. For example, a droplet of reagent containing permanganate or iron ions is applied to a surface of the current invention after it has been exposed to HP. A color change will occur based on the presence or sequestered HP
  • Additional antimicrobial characterization can be performed utilizing test methods described herein, and can include a wide range of pathogenic bacteria, including resistant strains such as MRSA and VRE.
  • Other organisms that could be tested include Enterococcus faecium, Escherichia coli, Pseudomonas aeruginosa , and Klebsiella pneumonia .
  • a time-kill study using E. coli and S. aureus can also be performed to determine the rate of induction of the antimicrobial effect.
  • testing against selected fungal organisms such as Candida albicans and Aspergillus niger ) can be carried out using appropriate methods (such as ASTM G21).
  • anti-viral efficacy of coated surfaces exposed to HP-based cleaning solutions can be measured against selected types of viruses using appropriate methods.
  • Preliminary life-cycle (extended use) testing of coatings can be done by evaluating basic antimicrobial efficacy of coatings subjected to repeated cleaning cycles (i.e. 25 ⁇ and 50 ⁇ with a scrubbing pad). Observations on the physical appearance and integrity of the coatings can be made.
  • the peroxide must be able to penetrate (diffuse) into the polymer matrix.
  • One factor that controls the penetration of peroxide into the polymer matrix includes hydrophilic character, since HP is a polar molecule like water.
  • Another factor that controls the penetration of peroxide into the polymer matrix is crosslink density. Polymers with a lower crosslink density will allow better penetration of HP solution. These same factors will also allow release of sequestered HP later when it is needed for antimicrobial effect by allowing water back into the polymer matrix in a reversible manner so that peroxide can be unsequestered and diffuse to the polymer surface in a controlled manner.
  • Hydrophilic character can be increased by adding hydrophilic agents or wetting agents, which may be either polymeric agents or low molecular weight agents.
  • hydrophilic agents or wetting agents which may be either polymeric agents or low molecular weight agents.
  • a polymer which absorbs between 0.5% and 20% (w/w) water will be useful in the practice of this invention, as this allows for penetration of HP, but does not cause extensive swelling or degradation of the polymer.
  • a preferred range is between 2% and 10% (w/w) absorption of water.
  • a method such as ASTM D570 may be used to determine water absorbance of the base polymer, or the polymer with metal derivative dispersed therein.
  • ABS Polyacrylonitrile
  • acrylonitrile butadiene styrene (ABS) polymer Acrylic
  • PMMA Acrylic
  • EVA Ethylene-Vinyl Acetate
  • EVA Ethylene vinyl alcohol
  • PTFE, FEP, PFA, CTFE, ECTFE, ETFE Fluoropolymers
  • Ionomers acrylic/PVC alloy, Liquid Crystal Polymer (LCP), Polyacetal (POM or Acetal), Polyacrylates (Acrylic), Polyacrylonitrile (PAN or Acrylonitrile), Polyamide (PA or Nylon), Polyamide-imide (PAI), Polyaryletherketone (PAEK or Ketone), Polybutadiene (PBD), Polybutylene (PB), Polybutylene terephthalate (PBT), Polycaprolactone (PCL), Polychlorotrifluoro
  • ZnO powder was mixed with water to make a 1% aqueous dispersion and was treated with 3% hydrogen peroxide solution. The mixture was stirred for 15 minutes and then dried to obtain the treated ZnO powder. The treated dried ZnO powder was found to have an antimicrobial effect which was approximately 2-logs greater than dried ZnO powder which had not been exposed to HP.
  • the 100% solids UV stock solution, acrylic UV-curable coating formulation designated as SS1 was mixed for 15 minutes until it is homogenous.
  • the stock solution in the proper portion is then mixed with a dispersive aid and small particle size (in the nano range) Zinc Oxide using a high speed mixer to obtain a slurry comprising about 20% ZnO.
  • the slurry is then incorporated into either a 2-roll mill or media milling machine to grind the oxide particles until no particles are seen in the Hegman grind gage.
  • the milled solution may be dissolved in a solvent and particle size analysis carried out.
  • the above milled 100% solids solutions are rod coated onto polyester substrates.
  • the coated substrate are sent into an in-line UV curable unit at 20 ft./min using a 300 WPI power setting. If the surface is slightly tacky the UV curing can be repeated (20 fpm/300 wpi) to obtain a completely dry and non-tacky surface.
  • a similar control can also be coated and cured using just the SS1 stock solution without ZnO. Comparative antimicrobial studies can be then carried out on the control sample (w/o ZnO), an untreated sample (with ZnO), and a sample (with ZnO) treated with hydrogen peroxide solution.
  • the UV curable PUD stock solution designated as WBS1 is mixed for 15 minutes until it is homogenous.
  • the above WBS 1 stock solution in the proper portion is then mixed with a pre-milled ZnO solution in water using a high speed mixer to obtain a final solution having about 10% nano ZnO based on dry weight of the coating.
  • the above UV PUD solution doped with nano ZnO is rod coated onto polyester substrates.
  • the coated substrate is dried at 110° C. for 2-5 minutes until it is completely dry to touch.
  • the dried coated substrate is then sent into an in-line UV curable unit at 20 ft./min using a 300 WPI power setting to completely cure the coating.
  • a similar PUD control can be coated, dried, and cured using just the WBS1 stock solution without the nano ZnO. Comparative antimicrobial studies can be then carried out on the control sample (w/o nano ZnO), an untreated sample (with nano ZnO), and a sample (with nano ZnO) treated with Hydrogen Peroxide
  • the reaction product of a mixture of zinc chloride and zinc nitrate with sodium hydroxide was dispersed in additional water and allowed to undergo several cycles of settling and decanting. This process removes the salt (NaCl and NaNO 3 ) by-products present in the binder. A portion of this washed ZH aqueous suspension was saved for use in experiments. Using another portion, the water was then replaced with ethanol for several cycles in order to achieve zinc hydroxide in dry ethanol. The ethanol of the resulting zinc hydroxide mixture can be displaced using HDODA (1,6-hexanediol diacrylate) monomer. This could not be done directly because water and HDODA are not miscible. The ethanol serves as an intermediate.
  • HDODA 1,6-hexanediol diacrylate
  • XR-NSF-UV-F2 Formulation Component Function Weight % Genomer 6083/HD Inert resin (polyurethane) in monomer. 30.0 Main binder for the coating. Genomer 4690 Aliphatic urethane hexaacrylate 30.0 Higher Crosslinking MIRAMER M280 Hydrophilic Oligomer 31.2 Tego Foamex N Defoamer 1.0 G16 stabilizer Oxidative Stabilizer 0.5 MP1200 Wax Detack 1.0 CPK Photoinitiator 5.0 Byk Silclean 3710 Surface Active Agent 1.2 Total 100.00
  • Zinc Peroxide (ZP), Zinc Hydroxide (ZH), and Zinc Oxide (ZO) solutions were then added into the stock solutions targeting either 10%, 15% or 20% pigment loadings as shown in the Table 1 below (PHR added is amount of pigment solutions based on 100 grams of stock solution to get the % loadings desired).
  • PHR added is amount of pigment solutions based on 100 grams of stock solution to get the % loadings desired.
  • the ZH could only be added at 10% due to the lower concentration (18.5%).
  • Example 5 The samples of Example 5 were exposed to 10% aqueous HP for one hour, then shaken to remove excess droplets of solution and allowed to dry for at least 72 hours at room temperature. The samples were tested for antimicrobial efficacy against Staph. aureus using ASTM E2180 “agar slurry” method, with an overnight exposure time. This same method is used in all of the following examples. All samples showed a “full kill” of SA (5.49 log reduction), as indicated in Table 2 below, in comparison to an untreated Mylar film not exposed to HP. Note that the term “Overnight” in the antimicrobial results refers to the difference in bacterial population between the sample and a negative control sample inoculated with the same bacterial load after both have been incubated overnight.
  • Example 5 The samples of Example 5 were then tested against E. coli (EC). Control samples and uncoated Mylar showed essentially no kill, as expected. Samples containing ZH and ZO showed full-kill (6.67 log-reduction) of EC. Results are shown in Table 3 below.
  • UV Curable PUD Formulation Component Function Weight % IPA Co-solvent 3.00 UCECOAT 7689 Water-borne UV Curable PUD 89.70 35% in water M380 Hydrophilic Oligomer 5.00 GENOCURE* LBC Oxidative Stabilizer 1.73 Irganox ® 1520 Photoinitiator 0.32 Dynol 607 Surface Active Agent 0.21 Total 100.0
  • WB-F1 was then doped with Nanobyk 3840 to get 10% and 20% ZO loadings respectively as shown in Table 4.
  • the coatings were coated on polyester substrates as summarized below.
  • WB-F2 was then doped with the water-borne Nano ZO (Nanobyk 3840) to get 10% and 20% ZO loadings respectively as shown in Table 4.
  • the coatings were coated on polyester substrates as summarized below.
  • the resin was dissolved in MEK at 30% solids to give high viscosity liquid. It was further modified with a surface active wetting agent (Byk3440). This stock solution was XR-NSF-SB-F1 (SB-F1 for short). SB-F1 was then doped with the solvent-based ZO Nanobyk 3841 to get 10% and 20% ZO loadings respectively as shown in Table 5.
  • the resin was dissolved in MEK at 40% solids to give high viscosity liquid. It was further modified with a surface active wetting agent (Byk3440). This stock solution was XR-NSF-SB-F2 (SB-F2 for short). SB-F2 was then doped with the solvent-based ZO Nanobyk 3841 to get 10% and 20% ZO loadings respectively as shown in Table 5. All the doped solutions based on C305 gelled. Most likely the ZnO formed a complex with the Crotonic acid and created crosslinked networks. Thus, no coatings were made with SB-F2 solutions.
  • Example 7 The water-borne coating systems (samples designated with prefix “W”) and solvent-borne coatings systems (samples designated with prefix S) of Example 7 were tested for antimicrobial activity using ASTM E2180 “agar slurry” method.
  • samples WB-F2, WBF1-20ZO, WBF1-10ZO, SBF1-20ZO, and SBF1-10ZO from Example 7 as well as samples UV-F2, F2-10ZH, F2-15ZO, and a blank Mylar film 7 were used for the present study.
  • the selected samples were exposed to 3% HP for one hour, and then tested for antimicrobial efficacy against EC after drying for at least 24 hours.
  • the water-borne (WB) samples of this example showed essentially zero efficacy. It will be seen in later examples that increasing the hydrophilic character of WB coatings will increase efficacy.
  • the solvent-borne sample SBF 1-20ZO again showed high efficacy. All the 100%-solids UV samples (15 and 20% ZO) showed great efficacy. Uncoated Mylar exposed to HP did not show any efficacy.
  • the water-borne self-crosslinking polyurethane dispersion based on Alberdingk U915 was modified by adding 25% (by weight solids) of a hydrophilic acrylic binder dispersion Alberdingk AC2570 (Stock Formulation XR-NSF-WB-F3).
  • the two dispersions were completely compatible and gave a clear “control” coating (0% ZnO).
  • the WB-F3 was then doped, separately, with 20% ZO and 30% ZO using Nanobyk 3840 ZO dispersion from Byk-Chemie.
  • the formulation scheme was as shown in Table 8 below.
  • the dispersions were coated on SKC's SH41 PET (Mylar) substrate using a #8 Wire Rod.
  • the dry coating weights (CW) were calculated as shown in Table 8 above. Both 20ZO and 30ZO gave excellent coatings on the PET substrate.
  • the self-crosslinking polyurethane dispersion/acrylic combination formulation (WB-F3) was “physically dry” after drying the water off and continued to develop its physical property due to self-crosslinking. The following coatings were prepared by this method.
  • thermoplastic polymers Two different thermoplastic polymers were studied as solvent-borne coatings.
  • SB-F1D-20ZO SB-F1D stock loaded with 20% Nano Zinc Oxide
  • SB-F3D-20ZO SB-F3D stock loaded with 20% Nano Zinc Oxide
  • SB-F3D-15ZO SB-F3D stock loaded with 15% Nano Zinc Oxide
  • This experiment outlines the preparation of water-borne coatings that incorporate a physically drying polyurethane dispersion rather than a self-crosslinking dispersion.
  • the new formulation was designated XR-NSF-WB-F4 and comprised 36% of the hydrophilic acrylic polymer.
  • thermoplastic polymers Two different thermoplastic polymers were studied as solvent-borne coatings.
  • SB-F1D-20ZO SB-F1D stock loaded with 20% Nano Zinc Oxide
  • SB-F3D-20ZO SB-F3D stock loaded with 20% Nano Zinc Oxide
  • Example 5 Table 1
  • Example 7 Tables 4 and 5
  • EC E. coli
  • SA S. aureus
  • Tables 12 and 13 Data for these previously-described coatings is summarized in Tables 12 and 13 below. Although there is some variation in data from the previous tests, some general trends are apparent. Most samples performed very well after 10% HP exposure. At lower concentrations (1% and 3%), the solvent-borne coating formulations did particularly well.
  • Sample S8 (SBF1-20ZO) was selected and a time-study for exposure to 3% HP was done. Samples were then tested against EC. We found that even after only 3 minutes exposure to HP, significant antimicrobial efficacy was apparent. Samples were tested after drying for at least 24 hours after HP exposure. See Table 14 for data. Sample S8 was also exposed to a commercial HP-based cleaning product (Clorox) containing 1.4% HP, but no efficacy was seen after simple wiping with the product.
  • Chrox commercial HP-based cleaning product
  • Valspar Bare Wood Primer was selected as a carrier for inclusion of ZnO particles since it was previously tested and showed zero inherent antimicrobial activity.
  • Samples were prepared with “high” and “low” ZnO content (approximately 15 and 30% ZnO solids basis was added—Sample # 104A and 104B, respectively).
  • Commercial ZnO powder micron sized, Aldrich Chemical
  • Samples of these coatings were exposed to 3% and 10% HP for one hour. Results are shown in Table 17. Both samples exposed to 10% HP showed high antimicrobial efficacy; however, a control sample (0% ZnO) also showed good efficacy after exposure to 10% HP. With 3% HP, both samples showed slight to moderate efficacy which was higher than that of the 0% control.
  • Formulations having even higher hydrophilic character than the previously described formulations of Examples 9 and 11 were prepared in a similar manner.
  • the water-borne coating compositions were made at 20 and 30% nano-ZnO (samples WBF4-30ZO and WBF4-20ZO).
  • the newer solvent-borne coating samples were prepared similar to the previous batch, but were made from more diluted coating solutions (Samples SBF1D-20ZO and SBF3D-30ZO). These were exposed to 3% HP for 1 hour, and tested against EC after drying for one day. Results are presented below in Table 18, and all the water-borne and solvent-borne coating samples showed high efficacy.
  • the exposure of sample 104A (Example 16, above) to 3% HP was also repeated, and the same moderate efficacy was observed.
  • sample WB F4D (20% ZnO) was tested for antimicrobial efficacy against other organisms after exposure to 10% HP for one hour, followed by drying for 24 hours.
  • the organisms tested included Staph. Aureus (SA), Methacillin-resistant Staph. Aureus (MRSA), Klebsiella Pneumonia (KP), and Enterococcus Faecium (EFm). All samples exhibited high antimicrobial efficacy (full kill) against these organisms, as shown in Table 20 below.
  • Water-borne coating formulations F4 (of Example 17) were exposed to 3% HP for either 5, 15, or 30 minutes, or treated with Clorox HP spray (1.4% HP) for 5 minutes. Samples were tested against EC after drying for 1, 3, and 7 days. Results are shown in Table 21. Efficacy at 1 and 3 days drying generally increased with increasing HP exposure time. For the 30% ZnO HP-exposed samples, efficacy diminished only slightly (if at all) between day 1 and day 3 or Day 7. The 20% ZO sample at 15 minute exposure was also run separately (both exposure and efficacy) in another series of assays and achieved similar results to the first set of testing. The 20% ZnO sample exposed to Clorox HP cleaner showed very high efficacy after 1 day, but no efficacy after 3 or 7 days dry storage. The 30% ZnO sample showed no efficacy after exposure to Clorox cleaner.
  • WB F3 samples were made at 20% nano-ZnO content. Samples were exposed to 3% HP for 30 minutes, and tested after 24 hours of drying. Time-kill profile: Note that all of the testing described in prior examples above has utilized an overnight (18-24 hour) bacterial contact (incubation) time. That is, samples are inoculated with bacteria and the residual viable bacteria are enumerated after 18-24 hours of exposure to the antimicrobial surface. We performed a time-kill study by looking at various contact times ranging from 5 minutes to overnight. Data was collected for EC and also for MRSA (methicillin-resistant Staph. aureus ). This data is presented in the Tables 23 and 24, below.
  • Peridox RTUTM a commercial hydrogen peroxide-based cleaner
  • the Peridox cleaner contains 4.4% HP and 0.23% peroxyacetic acid as the active ingredients.
  • Samples of WB F3 of Example 9 coating were exposed to Peridox for various time periods. Significant efficacy was observed for the 15 minute exposure (see Table 25). See also data in Table 26 of the next example.
  • Water-Borne Coating samples similar to the WB-F3 and WB-F4 formulations of Examples 1 and 13, were prepared using similar polymer formulations. However, micron sized ZnO (commercially available from Aldrich) was used instead of nano-ZnO used previously. Two formulations were made using the procedures of Examples 11 and 13. Sample 1120A was made using 21 g Alberdingk U915, 15 g H2O, and 2.6 g ZnO (Dry), which was then homogenized, followed by addition of 10 g Alberdingk AC2570 and mixing by hand.
  • Sample 1120B was made using 21 g Alberdingk U915, 10 g H2O, and 2.6 g ZnO (Dry), which was then homogenized, followed by addition of 15 g Alberdingk AC2570 and mixing by hand. In addition, a control sample (0% ZnO) was made. All were coated onto Mylar sheets. As shown Table 26 below, the samples with micron ZnO showed excellent efficacy after being exposed to 3% HP for 1 hour, or 10% HP for various times, or Peridox or Clorox HP cleaner for 5 minutes, followed by 24 hours drying.
  • a coatings formulation chosen from those described in the above examples is used to treat a textile article, which may comprise cotton, rayon, polyester, nylon, acrylic or other material.
  • the treatment may consist of wetting said textile with the coating formulation by spraying, dipping, padding or other means, followed by removal of excess coating liquid by means familiar to one skilled in the art, followed by drying of the treated article.
  • Said coating formulation may be diluted with solvent or water prior to treating the textile.
  • the dried textile will have ZnO particles immobilized on or in the textile. The ZnO particles can be activated to become antimicrobial by exposure to HP solution, such as during laundering.
  • Hydrogen Peroxide may be added to any coating formulation described in the above examples, particularly the aqueous-based systems. In this manner, the dried coatings will have antimicrobial efficacy even before subsequent exposure of the dried surface to HP solution.
  • a preferred amount of HP is at least 1% by weight of the dried coating.

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